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medium voltage AC (4160 VAC and 13.8 VAC) to low voltage DC 480V
(400 VDC) power conditioning system block (PCSB) that are 3000A @2500kVA
scalable so that they can be used for micro grids of different scale
(several-hundred kW to multi-MW). The modular approach is
intended to result in higher-volume, lower-cost, less-loss power
MV/480V
electronics building blocks that service many applications, such as 60Hz Transformer
Server Hall 1 Server Hall 2
DC data center and electric vehicle charge station. In this paper, a
225kW, 500 kHz PCSB is demonstrated to direct converter 4160 Fig. 1. Traditional LVAC Distribution before Sever Hall
VAC to 400V DC for a DC date center. WBG power devices and
CLLC resonant converter are used to minimize switching related MV Utility Service
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resulting high turn off loss. We will use CLLC resonant 12uH leakage inductance which is two times larger than that of
converter to build the DC/DC module as shown in Fig. 6. It type 2 6.1uH. Type 2 winding is verified work under lower flux
employs magnetizing inductance to achieve ZVS of primary density which generate lower eddy current loss.
switches for whole load range, and synchronize rectifier (SR)
control is used for secondary to reduce conduction loss. Turn
off current is only the peak current of magnetizing current.
Converter device loss breakdown under 15kW 100C is shown
in Fig. 7 based on 1.2 kV SiC MOSFET from GE (Primary side)
and 650V GaN device from GaN System (Secondary side). Up
to 500 kHz device loss is acceptable within 1% of total power.
Our research will start from 500 kHz, power level will be
around 15 kW for each DC/DC module.
2:1:1 Fig. 8. Transformer structure comparison between type 1 EE core (left) and
type 2 UU core (right)
800V Llk1 Llk2 400V
DC DC
Lm
Llk2
Pri. : Series
Sec: Parallel
Single Core
Fig. 6. CLLC converter with two parallel output sets Fig. 9. Magnetic field simulation comparison between type 1 EE core (left)
and type 2 UU core (right)
200 618
512
A. Transformer Structure Determination 150
100
500
256
422
46.1
23.3 8.4 16.6
Frequently used transformer structures are still EE core and 50
0 0
UU core structures shown in Fig. 8. For both of these two 100kHz 300kHz 500kHz 100kHz 300kHz 500kHz
Type1 Type2 Type1 Type2
structures sectionalized winding are employed to guarantee Fig. 10. Resonant capacitor value and stress comparison between two types
insulation capability. Gap between two core parts can be used to
insert a shielding board between primary and secondary coil to B. Transformer Isulation Design
increase both clearance and creep age distance. If we make a It is obvious that only the high frequency isolated
comparison between two structures, type 1 holds two times transformer can provide insulation safety function for overall
higher magneto motive force (MMF) value comparing to type 2 system and it should be designed based on the input medium
, moreover type1 holds shorter air flux path length (ld), all of voltage level 4160V. Insulation between primary high voltage
which results in larger leakage inductance and higher eddy winding and secondary low voltage winding and transformer
current loss comparing to type 2 structure. core should all designed based on 4160V insulation
3D FEA simulation is done in Maxwell and the magnetic requirement. However insulation between secondary winding
field simulation result is shown in Fig. 9 under same scale. It is and core only need to be designed based on 400V level.
obvious that type 1 holds higher magnetic field value among the According to IEEE Std. C57.12.01 standard [18], there are
window area because higher MMF value and shorter air flux at least 3 dielectric test need to be passed: basic lightning
path length. From leakage inductance point of view type 1 holds impulse, applied voltage and partial discharge tests. Lightning
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0.4
impulse test should have 30 kV crest value, and low frequency Ds T
apply voltage should be test up to 12 kV RMS value for the = ref
Ds ref T
4160V application shown in Tab II. The third insulation test is (1)
partial discharge test. TABLE V DIELECTRIC PARAMETER OF TRANSFORMER
Bobbin thickness 4 mm
TABLE II INSULATION TEST LEVEL FOR DRY TYPE TRANSFORMER OF IEEE
STD. C57.12.01 Primary insulation Tape thickness 2.2mm (14 layers)
Secondary insulation Tape thickness 0.35mm(2 layers)
Nominal Low- Basic Lightning impulse insulation Primary bobbin to core spacer 4 mm
L-L frequency levels(BIL ratings) in common use kV Secondary bobbin to core spacer 1 mm
system voltage crest(1.2*50us) Primary bobbin to secondary bobbin spacer 4 mm
voltages insulation Based on previous insulation design parameter. We build an
level
(kV) (kV rms) 10 20 30 45 60 95 110 electric field simulation in Maxwell to simulate the electric
0.25 2.5 None field distribution among all insulation material. Primary side
0.6 3 S 1 1 high voltage winding is connected to the high insulation test
1.2 4 S 1 1 voltage 30kV. Both transformer core and secondary winding is
2.5 10 S 1 1 grounded. Final simulation result is shown in Fig. 11. We can
5.0 12 S 1 1
8.7 20 S 1 1
see within the insulation solid material (bobbin, insulation tape,
15 34 S 1 1 and encapsulating material) maximum electric field is around
In order to pass IEEE Std. C57.12.01 standard, transformer 5.5kV/mm which is much smaller than that of all insulation
clearance distance and creep age distance should be designed solid material.
based on the transformer steady state operation voltage (4160V)
and transient maximum peak insulation test voltage (30 kV).
According to standard [19], for 4160 V operating voltage
minimum creep age distance should be at least 41.6 mm; for
30kV peak working voltage the minimum clearance distance
should be at least 42 mm. Besides these requirements all the
insulation solid material thickness like insulation tape and
bobbin should all designed based on maximum insulation
requirement 30kV.
Three different solid insulation material for transformer Fig. 11. Electric field simulation under highest insulation test voltage 30kV
bobbin are shown in Tab III. PTFE is chosen as insulation
bobbin material with high dielectric strength (19.7 kV/mm) and C. Core Material Selection and Magnetic Loss Modeling
high working temperature. Another three different insulation According to survey mostly used core materials are
tape candidates are compared in Tab IV. 3M 8943 is chosen as Nanocrystalline and Ferrite. For our target 500 kHz application
dielectric tape for high dielectric strength (9.8 kV/0.17mm) and Nanocrystalline is ruled out due to their high core loss density at
high thermal conductivity (0.4 W/ mK). such high working frequency range comparing to Ferrite. MnZn
TABLE III TRANSFORMER BOBBIN MATERIAL CANDIDATES COMPARISON Ferrite is our material candidate. There are plenty of MnZn
Ferrites for our 500 kHz application. We compared five material
Material Candidate PTFE PC ABS candidates in Fig. 12 to figure out the appropriate Ferrite
Dielectric Strength@25C 19.7kV/mm 15 kV/mm 16.7 kV/mm
material. 3F36 holds lower loss comparing to other competitors
Dielectric Constant 2.1 2.9 2.87
Thermal conductivity 0.25 W/mK 0.22 W/mK 0.17 W/mK and is chosen as our core material.
High working temperature 250C 130C 100C 1000
Thermal conductivity 0.4 W/mK 0.1 W/mK 0.2 W/mK P61 ACME
Stable Temperature -40~200C -73~260C Up to 950C PC95 TDK
10 3C98-- Ferroxcube
Note that plastic material dielectric strength reduces when 3F45 -- Ferroxcube
material thickness increases. Rule of thumb relationship is 3F36 Ferroxcube
100 C
listed in equation (1) [20]. Ds is dielectric strength under 1
10 100
specific thickness T, Dsref is reference dielectric strength under Bmax(mT)
reference thickness Tref. Considering 50% margin, 45kV is
chosen to determine insulation thickness calculated result is
Fig. 12. MnZn Ferrite candidates core loss comparison @500kHz
shown in Tab. V. Besides this we also encapsulate primary high
voltage winding with epoxy material (EPIC Resin
The state of art core loss calculation method is Steinmetz
R1055/H5083) to eliminate insulation weakness and avoid
Equation:
moisture and dust on high voltage winding.
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Pv = k f Bm (2)
Then Transformer core loss can be calculated based on Where N is transformer turn number, Ns is litz wire strand
RESE method by multiplying core volume with core loss number, lw is length per turn, <>j is space average calculator
density under square voltage excitation shown in equation (4). over j turn winding. There is still two dependent variable N and
Where Vpri is the primary side DC voltage, N is the turn number t. From time domain point of view, the magnetic field is a quasi-
of primary side, lc is the magnetic loop length of the core. Note sinusoidal shape and here we assume it is sinusoidal shape and
that there is only one dependent variable that is transformer turn time average eddy current loss calculation is give below in (7)
number.
N
02 lw d s 4 dH m sin( wt ) 2 (7)
V pri Peddy ( N ) = N s ( )
Pcore ( N ) = Pv _ rec lc
(4) j =1 64 c dt j
4 N Bm f
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gives smaller transformer section area and smaller total TABLE VI TRANSFORMER DESIGN PARAMETER
transformer volume. Under certain core loss density, the core Working Frequency(fs) 500 kHz
loss will decrease. At same time larger transformer turn number Core Material 3F36
will increase total transformer winding length which resulting Core loss density(Pv) 300kW/m3
in higher winding loss. Finally summation of both core loss and Strand AWG 44
winding loss contribute to transformer total loss U shape curve Litz wire stand number(Ns) 825
can be plot shown in Fig. 14. Turn Number(N) 12
Winding loss 36 W
110
Core loss 38 W
100
Total loss Transformer volume 0.37 Liter
90
Magnetizing inductance 28uH
80
70
60
50
Winding loss
A. Transformer Prototype and Parasatic Inductance Test
40
Core loss
30
Based on previous transformer designed parameters shown
20
6 8 10 12 14 16 18 20
in Tab VI, medium voltage high frequency transformer
N
prototype is developed shown in Fig. 17. Dimension marked is
including mechanical fixture. Transformer gap value is
Fig. 14. Transformer loss vs transformer turn number N determined by transformer magnetizing inductance. Parasitic
leakage inductance and magnetizing inductance is measured
Following the same method, considering core loss density and shown in Tab VII. At same time 3D FEA simulation results
impact, we swept Pv from 100 to 400 kW/m3 and plot of leakage inductance and magnetizing inductance is also
transformer total loss vs transformer turn number as shown in shown in Tab VII.
Fig. 15. The optimal design valley region is slightly moved to
higher turn number when core loss density increases. In order
to figure out our transformer design point. Then we plot
transformer total loss vs transformer volume relationship in Fig.
16, each mark with the curve represent one transformer turn
number design point. Transformer volume is calculated based
on minimum box volume that transformer can be put into
(Mechanical fixture volume is not included). Final design point
(N=12, Pv=300) locate around the corner region as the trade-off
between volume and total loss. Transformer design parameter
is summarized and shown in Tab VI.
120 Fig. 17. Medium voltage 500 kHz transformer prototype
Pv =400 kW/m3
110
Pv =300 kW/m3 TABLE VII TRANSFORMER DESIGN PARAMETER
100 Pv =200 kW/m3
Pv =100 kW/m3 Parasitic parameters Prototype Test 3D FEA
Loss /W
90
80
Magnetizing Inductance(Lm) 27.78uH 28uH
Primary Leakage Inductance(Lrp) 6.76uH 6.1uH
70
Secondary Leakage Inductance 1(Lrs2) 4.33uH 3.6uH
60 Secondary Leakage Inductance 2(Lrs2) 4.26uH 3.6uH
50
6 8 10 12
N
14 16 18 20
B. Transformer Medium Voltage Insulation Test
After transformer prototype is built up, since target
Fig. 15. Transformer loss vs turn number N application is 4160V medium voltage, insulation safety should
120
be first concern. In order to verify transformer insulation
110
Pv =400 kW/m3 capability for 4160V medium voltage application, the
Pv =300 kW/m3 transformer prototype is tested under previous mentioned IEEE
100
Pv =200 kW/m3 Std. C57.12.01 insulation standard. Three insulation test is
Loss /W
90
Pv =100 kW/m3 conducted including basic lightning insulation test, applied
80
voltage insulation test, partial discharge insulation test all of
70 which will be talked about in the following separately.
60 Total loss=74W According to IEEE Std. C57.12.01, for 4160V application
50
Volume=1.02Liter transformer the basic lightning insulation test should be at least
0.9 1 1.1 1.2 1.3 1.4 1.5 1.6
Volume /L 30kV. The voltage waveform is also presented in the figure.
Within 1.2us the test voltage should be increased to 30kV peak
Fig. 16. Transformer loss vs transformer volume trade-off value and gradually go down to half of peak value at 50us.
During the test if the test voltage waveform is smooth and no
collapse happens during the waveform going down. This means
the transformer passes this lightning test. Then the transformer
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is tested under thus condition test waveform is also in Fig. 19. one more equipment is added that is partial discharge
Test waveform meets the requirement and shapes smoothly measurement unit shown in Fig. 21. This unit can measure the
going down. Blue and red curves represent two independent test. transformer dynamic partial discharge value during the whole
Two test waveforms agree with each other and overlap very test process. The test voltage requirement is shown in Fig. 21.
well. Based on these test results, we conclude that our Our partial discharge test result is 3.8 pC which is much smaller
transformer passes the basic lightning insulation test. than 50 pC of IEEE standard requirement during 5.4kV
3minutes period.
Fig. 21. Transformer under partial discharge test and test condition
Fig. 18. Transformer under basic lightning insulation test and connection V. CLLC CONVERTER EXPERIMENT TEST
Finally 500 kHz 15kW CLLC resonant Converter is
developed based on our medium voltage high frequency
transformer shown in Fig. 22. The power density reaches 48
kW/in3. We gradually increase converter power level, the
waveform of 15kW full power load is shown in Fig. 23. The
dead time is around 80ns and turn off current of primary side
device is around 12A. Zero voltage switching is achieved with
little oscillation due to hard switch turn off.
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In order to achieve high efficiency power conversion [6] Zhao, T.; Wang, G.; Bhattacharya, S.; Huang, A. Q., "Voltage and Power
secondary side GaN device need to work at synchronize Balance Control for a Cascaded H-Bridge Converter-Based Solid-State
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98%
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97%
96%
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94% [10] G. Y. Wang, S. Baek, J. Elliott, A. Kadavelugu, F. Wang, X. She, S.
93% Dutta,Y. Liu, T. F. Zhao, W. X. Yao, R. Gould, S. Bhattacharya, and A.
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[11] J.S.Lai, A.Maitra, A.Mansoor, and F.Goodman, Multilevel intelligent
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Fig. 24. 500 kHz CLLC converter efficiency test result [12] Xu She; Xunwei Yu; Fei Wang; Huang, A.Q. "Design and Demonstration
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.Magnetic loss model of both core loss and winding loss are Challenges and Opportunities ECPE Workshop "Smart Transformers for
presented based on which transformer design trade-off between Traction and Future Grid Application", Zurich, Switzerland, February 4-
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